Research and Reflections on the Safety of Automotive Lithium-ion Batteries

Abstract

This article provides a comprehensive analysis of safety challenges in lithium-ion batteries for electric vehicles (EVs) and proposes mitigation strategies to address these risks. Li-ion batteries, while pivotal for EVs adoption due to their high energy density and efficiency, face critical safety concerns such as thermal runaway, mechanical deformation, and electrochemical instability. Thermal runaway—triggered by mechanical collisions, electrical abuse (overcharging, over-discharging), or internal short circuits—remains the most severe hazard, often leading to fires or explosions through exothermic reactions, electrolyte decomposition, and gas release. Mechanical failures, including structural damage from crashes or vibration, exacerbate risks by inducing internal short circuits and heat accumulation. Current safety measures emphasize advanced battery management systems (BMS) for real-time voltage, current, and thermal monitoring, alongside thermal management systems (TMS) utilizing liquid cooling, phase-change materials, and micro heat pipe arrays to enhance heat dissipation. Material innovations, such as flame-retardant additives, solid-state electrolytes, and silicon anodes, aim to reduce flammability and dendrite formation. Structural protections, including reinforced housings and optimized cell-to-pack designs, further improve crash resilience. Future directions highlight AI-driven fault prediction, in-situ diagnostics, solid-state battery development, and sustainable recycling methods. This study underscores the necessity of multidisciplinary approaches integrating electrochemistry, mechanical engineering, and data analytics to advance battery safety, ensuring EVs meet rigorous reliability standards and foster public confidence in sustainable transportation.